application guide metalscan ms4000 series for ge …
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APPLICATION GUIDE
MetalSCAN MS4000 SERIES FOR GE LM2500 GAS TURBINES
MetalSCAN MS4000 for GE LM2500 Gas Turbines Application Guide gastops.com
Real-time damage detection. Anytime. Anywhere.
MetalSCAN enables gas turbine operators to maximize equipment availability by providing the industry’s earliest advance warning of potential damage events.
Overview
Designed for the GE LM2500 or LM2500+ gas turbine engine, the MetalSCAN online oil debris system easily installs into the gas turbine lube oil scavenge line.
MetalSCAN is a full flow, nonobstructive, online debris detection system designed to detect the onset of surface fatigue of bearings and gears. It is used as a condition monitoring device to determine the condition of the gas generator, accessory gearbox and Power Turbine (if fitted).
MetalSCAN oil debris monitoring system is available in two variants, either as an MS4000 Multi-Sensor system installed upstream of the scavenge pump in the individual oil scavenge lines; or as an MS4110 Single-Sensor system installed into a common line before the filter, downstream of the scavenge pump.
The engine and accessories are monitored continuously, allowing for early detection and tracking of the progressive deterioration of any damaged bearings or gears in real time. The sensors are installed in the lubrication oil lines with standard flanges and fittings adapted to the turbine configuration. Users can select either the simpler MS4110 Single-Sensor or the full MS4000 Multi-Sensor solution for enhanced coverage.
Several convenient data communication options are available to suit specific needs including direct connection to the engine controller, an existing Host Monitoring System, or by a fully standalone PC connection.
MS4110 Single-Sensor SystemA single MetalSCAN sensor is plumbed downstream of the oil scavenge pump combining the lines from the A-Sump, B-Sump, C-Sump, Accessory Gearbox and the Power Turbine (D-Sump), if fitted. The sensor is mounted using standard mounting bracket to the engine enclosure. The sensor connects to the MetalSCAN Electronic Control Unit (ECU) mounted to the outside of the engine enclosure via a 20-ft. sensor cable.
MS4000 Multi-Sensor SystemFour MetalSCAN sensors are plumbed into the four Gas Generator (GG) lube oil scavenge lines for the A-Sump, B-Sump, C-Sump, Accessory Gearbox and the Power Turbine (D-Sump), if fitted. Each sensor is mounted on a sensor stand which is secured inside the engine enclosure. The sensors individually connect to the MetalSCAN Electronic Control Unit (ECU) mounted to the outside of the engine enclosure via 20-ft sensor cables.
MetalSCAN installed into the A-Sump, B-Sump, C-Sump and AGB scavenge lines.
Physical Installation
gastops.comMetalSCAN MS4000 for GE LM2500 Gas Turbines Application Guide
Physical Installation The ECU is connected via RS485 Modbus protocol serial communication to a host PC computer or directly to the facility control system.
The entire installation of the MetalSCAN system can typically be completed in less than two days with Field Service Support for installation supervision and commissioning available from Gastops. The installation hardware, warning and alarm settings are included with the Installation Kit options.. and are available for the LM2500 and LM2500+ with either the 2-stage Low Speed Power Turbine (LSPT), the 6-stage High Speed Power Turbine (HSPT) or the Dresser-Rand Vectra Power Turbine.
gastops.comMetalSCAN MS4000 for GE LM2500 Gas Turbines Application Guide
Option 1Direct
Integration
Option 2Gastops
Integration
Controller
OR
Monitoring System
MetalSCAN Monitor
MetalSCAN Remote
Guideline Multi-Sensor Single-Sensor Benefit Summary
Individual sump debris detection Allows for individual sump isolation
Earliest indication Damage particles reach sensor immediately
Trending & limits Trend to sump alarm or combined alarm
Remote monitoring Less local involvement
Active load adjustment Load reduction to augment RUL trend projection
Troubleshooting Early detection enhances advanced troubleshooting
Proactive planning Early detection and trending supports planning
Peaker operation Opportunity for a more affordable and easy retrofit
Savings delivered User feedback: $100k to $1M+ per detection event
Repair benefits Damage has been isolated early and did not spread
Cost $$$ $ Installation < 1 day (single) vs 2 days (multi)
MetalSCAN Selection Guide
Data
Actions
N/A Base solution Optimal solutionGood solution
ROI
Proven and adapted solutions for LM2500 and LM2500+ with the LSPT, HSPT and Vectra PT.
gastops.comMetalSCAN MS4000 for GE LM2500 Gas Turbines Application Guide
Condition Monitoring
Once installed, the sensors detect the presence of metallic particles to provide early detection, identify severity, and provide remaining life indication of the bearings and gears located deep within the equipment.
The MetalSCAN sensors detect metal particles above the minimum size threshold and provide particle data, equipment condition and self-diagnostic information to the engine controller, an existing Host Monitoring System, or via an optional standalone PC.
The information collected by each sensor is compared to pre-established machinery condition indicators. These condition indicators are based upon simple criteria which determine whether the equipment is healthy. When damage is detected, condition indicator models help determine how much damage there is and how much longer the equipment can be operated before a potential failure. All analysis is performed locally to the ECU and subsequently transmitted to a host monitoring system.
Increased insight and visibility into the health of the equipment allows for proactive health assessment, enabling effective maintenance planning and empowering operators with real-time knowledge of equipment health.
Software and Services
When connected through the local RS-485 network, MetalSCAN can be interfaced to a MetalSCAN Monitor, a completely client-hosted stand-alone software platform that enables operators to host, monitor and analyse the data locally. MetalSCAN Monitor is a user-friendly software that lends itself to operators with all levels of experience and is designed for monitoring all types of gas turbines and fleet sizes. MetalSCAN Monitor also allows operators to interface to external data acquisition or monitoring systems.
MetalSCAN Monitor can be connected to Gastops MetalSCAN Remote Web-portal, enabling a complete Condition Assessment and Analytics Monitoring Service. The portal provides users with detailed health indicators for each asset, a customisable watchlist for the entire fleet and fully customizable warning, alarm and event notifications. Data is posted on the portal near real-time and allows for customized reporting and cross comparisons of assets by type, location, or any other key characteristic. Operators can also import data and reports in several supported formats or interface to 3rd party systems via a Rest API.
Users can easily subscribe and renew their MetalSCAN Support Service Package which includes monitoring by Gastops analytics team along with monthly reporting on key health indicators for each turbine, as well as observations and recommendations for the entire fleet.
Ordering Information MetalSCAN System and Installation Kit Order CodesTo place an order or request a quote, email us at [email protected] or call +1 613 744 3530.
Turbine Type MetalSCAN System Installation Kit Order Code Order CodeLM2500 w/ HSPT MS4000 System - 04M LM2500 - 03 & LM2500 - 05LM2500+ w/ HSPT MS4000 System - 04M LM2500 - 03 & LM2500 - 05 & LM2500 - 06LM2500 w/ LSPT MS4000 System - 05M LM2500 - 03 + LM2500 - 04LM2500+ w/ LSPT MS4000 System - 05M LM2500 - 03 + LM2500 - 04 & LM2500 - 06LM2500 w/ VECTRA PT MS4000 System - 05M LM2500 - 03 + LM2500 - 12LM2500+ w/ Vectra PT MS4000 System - 05M LM2500 - 03 + LM2500 - 12 & LM2500 - 06LM2500 (Common Scavenge Install) MS4110 System Contact GastopsOthers Contact Gastops Contact Gastops
Options and AccessorriesTo help you integrate the MetalSCAN MS4000 or MS4110 System into your equipment, we offer options and accessories such as computers, ATEX barrier kits, junction boxes, stainless steel enclosures, as well as software and remote services.
Product Order CodeMetalSCAN Computer (PC or Laptop) Option - 01AMetalSCAN Industrial Computer (CPU only) Option - 01BField Support Services for Installation Option - 03MS4000 Stainless Steel Enclosure Option - 07MetalSCAN Performance Test Kit Option - 11MetalSCAN Support Service Package Option - 12ATEX Barrier Kit Option - 17MS4110 Junction Box Option - 21MetalSCAN Monitor Software Option - 22
[email protected] | +1 613 744 3530
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